Manufacturing method of absorbent article

ABSTRACT

A method of manufacturing an underpants-type absorbent article having an outer body provided with a mutually separate front piece, back piece and connecting sheet, and wherein the front piece and the back piece are mutually joined at side areas and are mutually connected by the connecting sheet extending in the front-to-rear direction at the crotch area, and an inner body containing an absorptive body and which is overlapped and anchored to the connecting sheet on the inside of the outer body, comprises, in turn, transporting a continuous body of the front piece in the form of a front piece web and a continuous body of the back piece in the form of a back piece web in a machine direction while maintaining a spacing area in a cross-machine direction, forming a continuous body of the outer body in the form of an outer body web by attaching the connecting sheet to the front piece web and the back piece web at intervals in the machine direction so as to straddle the spacing area, cutting the outer body web in order to form edges that define leg holes, and attaching the inner body to the outer body web.

RELATED APPLICATION

This application is a 35 U.S.C. §371 national phase filing ofInternational Patent Application No. PCT/JP2010/073896, filed Dec. 28,2010, through which and to which priority is claimed under 35 U.S.C.§119 to Japanese Patent Application No. 2010-019807, filed Jan. 29,2010.

TECHNICAL FIELD

The present invention relates to a manufacturing method of an absorbentarticle.

BACKGROUND ART

A method is known in the prior art of manufacturing an underpants-typeabsorbent article, which is provided with an outer body, which isprovided with a mutually separate front piece, back piece and connectingsheet, and wherein the front piece and the back piece are mutuallyjoined at side areas and mutually connected by the connecting sheetextending in the front-to-rear direction at the crotch area, and aninner body containing an absorptive body and which is overlapped andanchored to the connecting sheet on the inside of the outer body,including: a transport step for transporting a continuous body of thefront piece in the form of a front piece web and a continuous body ofthe back piece in the form of a back piece web in a machine directionwhile maintaining a spacing area in a cross-machine directionperpendicular to the machine direction, an outer body web forming stepfor forming a continuous body of the outer body in the form of an outerbody web by attaching the connecting sheet to the front piece web andthe back piece web at intervals in the machine direction so as tostraddle the spacing area, an attachment step for attaching the innerbody to the outer body web, and an edge forming step for cutting theouter body web to form edges that define leg holes (see PLT 1). Namely,in this manufacturing method, a portion of the inner body is cut andremoved after having attached the inner body to the outer body web.

On the other hand, a method is known in the prior art of manufacturingan absorbent article that is formed from an outer body that integrates afront piece and back piece into a single unit, including: a transportstep for transporting a continuous body of the outer body in the form ofan outer body web, an edge forming step for cutting the outer body webto form edges that define leg holes, and an attachment step forattaching the inner body to the outer body web (see PLT 2).

CITATION LIST Patent Literature

-   PLT 1: Japanese Patent No. 3732459-   PLT 2: Japanese Patent No. 3599722

SUMMARY OF INVENTION Technical Problem

However, in the case of cutting and removing a portion of an inner bodyin the manner of the manufacturing method of PLT 1, there is the risk ofmistakenly cutting and damaging the absorptive body. Namely, there isthe risk of damaging the material of the finished product. If thematerial of the finished product is damaged, the resulting material canno longer be used as a product thereby resulting in the risk of adecrease in productivity of the absorbent article.

With respect to this point, the aforementioned problem may be able to besolved by first cutting an outer body web and then attaching the innerbody to the outer body web in the manner of PLT 2.

However, although subsequently described in detail, in a manufacturingmethod of an absorbent article in which the front piece and back pieceare formed from separate sheets, there is the characteristic problem ofthe risk of product members not being reliably connected. In PLT 2, thischaracteristic problem does not occur provided the absorbent article isformed from an outer body in which the front piece and back piece areintegrated into a single unit.

Namely, even if considering PLT 2, the problem of reliably connectingthe product members while simultaneously preventing damage to thematerial of the finished product cannot be solved.

Solution to Problem

According to the present invention, a manufacturing method of anunderpants-type absorbent article is provided, which is provided with anouter body, provided with a mutually separate front piece, back pieceand connecting sheet, and wherein the front piece and the back piece aremutually joined at side areas and are mutually connected by theconnecting sheet extending in the front-to-rear direction at the crotcharea, and an inner body, containing an absorptive body and which isoverlapped and anchored to the connecting sheet on the inside of theouter body, comprising, in turn: a transport step for transporting acontinuous body of the front piece in the form of a front piece web anda continuous body of the back piece in the form of a back piece web in amachine direction while maintaining a spacing area in a cross-machinedirection perpendicular to the machine direction, an outer body webforming step for forming a continuous body of the outer body in the formof an outer body web by attaching the connecting sheet to the frontpiece web and the back piece web at intervals in the machine directionso as to straddle the spacing area, an edge forming step for cutting theouter body web in order to form edges that define leg holes, and anattachment step for attaching the inner body to the outer body web.

Advantageous Effects of Invention

Product members can be reliably connected while simultaneouslypreventing damage to the product members.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a diaper of a first embodiment accordingto the present invention.

FIG. 2 is a plan view of a diaper that has been opened up by unfasteningjoining portions positioned at side areas.

FIG. 3 is a longitudinal cross-sectional view taken along line of FIG.2.

FIG. 4 is a lateral cross-sectional view taken along line IV-IV of FIG.2.

FIG. 5 is a general schematic diagram for explaining a method ofmanufacturing diapers.

FIG. 6 is partial schematic diagram for explaining a method ofmanufacturing diapers.

FIGS. 7(A), 7(B) and 7(C) are drawings of a top sheet web as viewed fromarrows A, B and C of FIG. 6.

FIG. 8 is a drawing showing an adhesive application pattern.

FIGS. 9(A) and 9(B) are drawings of other examples of adhesiveapplication patterns.

FIG. 10 is an open plan view for explaining a second embodimentaccording to the present invention.

FIG. 11 is an open plan view for explaining a third embodiment accordingto the present invention.

FIG. 12 is a partial schematic diagram for explaining a manufacturingmethod of a third embodiment according to the present invention.

FIG. 13 is an open plan view for explaining a fourth embodimentaccording to the present invention.

FIG. 14 is an open plan view for explaining a fifth embodiment accordingto the present invention.

FIG. 15 is a drawing for explaining a sixth embodiment according to thepresent invention.

FIG. 16 is a cross-sectional view taken along line XVI-XVI of FIG. 15.

FIG. 17 is a schematic diagram for explaining a diaper manufacturingmethod of a sixth embodiment according to the present invention.

FIG. 18 is a drawing for explaining a seventh embodiment according tothe present invention.

FIG. 19 is a drawing for explaining an eighth embodiment according tothe present invention.

FIG. 20 is a drawing for explaining a ninth embodiment according to thepresent invention.

FIG. 21 is an open plan view for explaining an undesirable example of anend portion.

DESCRIPTION OF EMBODIMENTS

The following provides an explanation of the present invention in thecase of applying to a disposable underpants-type diaper. Note that thepresent invention can also be applied to other underpants-type absorbentarticles worn in the manner of an undergarment.

With reference to FIG. 1 showing a first embodiment according to thepresent invention, a diaper 1 is provided with an outer body 2 and aninner body 3.

The outer body 2 is provided with a mutually separate front piece 4,back piece 5 and connecting sheet 6. In addition to being mutuallyjoined at side areas 1F, the front piece 4 and the back piece 5 aremutually connected by the connecting sheet 6 extending in thefront-to-rear direction FR in a crotch area 1C. Here, when worn, thefront piece 4 is positioned on the abdominal side of the wearer, and theback piece 5 is positioned on the back side of the wearer. In addition,the diaper 1 is provided with a waist opening or waist hole 1W definedby an upper edge 4U of the front piece 4 and an upper edge 5U of theback piece 5, and a pair of leg openings or leg holes 1L. In this case,each leg hole 1L is defined by an edge 1LE, and this edge 1LE is formedby a lower edge 4L of the front piece 4, a lower edge 5L of the backpiece 5, and both edges 6S in the transverse direction LT of theconnecting sheet 6. On the other hand, the inner body 3 contains anabsorptive body, and is overlapped and anchored to the connecting sheet6 on the inside of the outer body 2.

With reference to FIG. 2 showing the diaper 1 when opened up, the frontpiece 4 has a rectangular shape. The upper edge 4U of the front piece 4extends linearly in the transverse direction LT. On the other hand, thelower edge 4L of the front piece 4 is provided with a central portion4LC positioned substantially in the center in the transverse directionLT and side portions 4LS on both sides in the transverse direction LT ofthe central portion 4LC, the central portion 4LC extends substantiallyin transverse direction LT, and the side portions 4LS are slightlycurved towards the upper edge 4U. In addition, both side edges 4S in thetransverse direction of the front piece 4 extend substantially in alongitudinal direction LN. The longitudinal direction LN isperpendicular to the transverse direction LT.

In addition, the back piece 5 has a hexagonal shape protruding towardsthe front piece 4. Namely, the back piece 5 is provided with arectangular waist portion 5W and a trapezoidal extending portion 5E thatextends from the waist portion 5W towards the front piece 4. The upperedge of the back piece 5, namely the upper edge 5U of the waist portion5W, extends substantially in the transverse direction LT. On the otherhand, the lower edge of the back piece 5, namely the lower edge 5L ofthe extending portion 5E, is provided with a central portion 5LCpositioned substantially in the center in the transverse direction LTand side portions 5LS on both sides in the transverse direction LT ofthe central portion 5LC, the central portion 5LC extends substantiallyin the transverse direction LT, and the side portions 5LS are slightlycurved towards the upper edge 5U while extending at an angle withrespect to the transverse direction LT. In addition, both side edges 5Sin the transverse direction of the back piece 5 extend substantially inthe longitudinal direction LN.

When opened up as shown in FIG. 2, the front piece 4 and the back piece5 are arranged while separated by a spacing area SP in the longitudinaldirection LN perpendicular to the transverse direction LT. Theconnecting sheet 6 extends in the longitudinal direction LN bystraddling this spacing area SP substantially in the center in thetransverse direction LT of the front piece 4 and the back piece 5, andis respectively anchored to the front piece 4 around the lower edge 4Land the back piece 5 around the lower edge 5L, namely the extendingportion 5E.

The connecting sheet 6 has a shape in which narrowed portions areprovided in both sides of a rectangular shape substantially in thecenter in the longitudinal direction LN. In this case, the length and/orwidth of the connecting sheet 6 in the transverse direction LT isshorter than the width of the front piece 4 and the back piece 5 in thetransverse direction LT, and the length of the connecting sheet 6 in thelongitudinal direction LN is also shorter than the length of the innerbody 3 in the longitudinal direction LN. In addition, the side edges 6Sof the connecting sheet 6 are provided with a central portion 6SCsubstantially in the center in the longitudinal direction LN and endportions 6SE positioned on both sides in the longitudinal direction ofthe central portion 6SC, the central portion 6SC is curved inward, andthe end portions 6SE extend substantially in the longitudinal directionLN. In other words, the end portions 6SE do not coincide with the edgesof the outer body 2 that define the leg holes 1L, namely the lower edge4L of the front piece 4 and the lower edge 5L of the back piece 5, butrather are positioned farther to the inside in the transverse directionLT than the lower edges 4L and 5L. Note that the end portions 6SEcorrespond to both edges in the transverse direction LT of the portionsof the connecting sheet 6 that overlap with the front piece 4 and theback piece 5. In addition, both end edges 6E in the longitudinaldirection LN of the connecting sheet 6 extend substantially in thetransverse direction LT.

On the other hand, the inner body 3 has a rectangular shape that extendsin the longitudinal direction LN. Both side edges 3S in the transversedirection LT of the inner body 3 extend substantially in thelongitudinal direction LN, while both end edges 3E in the longitudinaldirection LN extend substantially in the transverse direction.

In addition, a pair of leakage preventing members 7 is provided on bothsides in the transverse direction LT of the inner body 3 along both sideedges 38 of the inner body 3. The free edges and/or outer edges 7S0 inthe transverse direction LT of the leakage preventing members 7 extendin the longitudinal direction LN.

As was previously described, the inner body 3 is overlapped and anchoredon the connecting sheet 6. In this case, the inner body 3 extends in thelongitudinal direction LN beyond the connecting sheet 6 and is alsoanchored to the front piece 4 and the back piece 5.

In addition, in this case, at least a portion of the central portion 6SCof both side edges 6S of the connecting sheet 6 are positioned fartherto the inside in the transverse direction LT than the outer edges 7SO ofthe leakage preventing members 7, and are also positioned farther to theinside in the transverse direction LT than both side edges 3S of theinner body 3. In contrast, the end portions 6SE of both side edges 6Sare positioned farther to the outside in the transverse direction LTthan both side edges 3S of the inner body 3, and are also positionedfarther to the outside in the transverse direction LT than the outeredges 7SO of the leakage preventing members 7.

As shown in FIG. 3, the front piece 4 is provided with two sheets,namely, a top sheet 4T that faces the wearer when worn and a back sheet4B that faces to the outside when worn, and the top sheet 4T and theback sheet 4B are mutually overlapped. Similarly, the back sheet 5 isalso provided with two sheets, namely, a top sheet 5T that faces thewearer when worn and a back sheet 5B that faces to the outside whenworn, and the top sheet 5T and the back sheet 5B are mutuallyoverlapped.

On the other hand, the connecting sheet 6 is formed from a single sheet.The sheet in this case may be liquid permeable or liquid impermeable.

This being the case, the connecting sheet 6 is softer than the frontpiece 4 and the back piece 5. Note that the quantity, material or basisweight and the like of the sheet that forms the connecting sheet 6 canbe selected so as to be softer than the front piece 4 and the back piece5. The degree of softness of the sheet material can be measured by, forexample, a cantilever method.

In addition, in the example shown in FIG. 2, the connecting sheet 6 isattached to the inside and/or wearer side of the front piece 4 and theback piece 5, namely to the top sheets 4T and 5T. However, theconnecting sheet 6 may also be attached to the outside of the frontpiece 4 and the back piece 5, namely to the back sheets 4B and 5B.Alternatively, the areas around both ends in the longitudinal directionLN of the connecting sheet 6 may be made to be sandwiched between thetop sheets 4T and 5T and between the back sheets 4B and 5B. Whereupon,both areas around the ends of the connecting sheet in the longitudinaldirection LN are not exposed on the sides of the top sheets 4T and 5T orthe back sheets 4B and 5B, thereby resulting in better touch to theskin. In addition, the connecting sheet 6 is more resistant toseparation from the front piece 4 and the back piece 5.

Here, the top sheets 4T and 5T and back sheets 4B and 5B of the frontpiece 4 and the back piece 5 as well as the connecting sheet 6 are eacha non-woven fabric formed from synthetic fibers such as polyolefin-basedfibers in the manner of polypropylene (PP) or polyethylene (PE) orpolyethylene terephthalate (PET)-based fibers, are formed from anon-woven fabric manufactured by spunbonding or air-through bonding, andeach has a basis weight of, for example, 13 g/m² to 30 g/m². In thefirst embodiment according to the present invention, the top sheets 4Tand 5T are respectively formed from an SMS non-woven fabric having abasis weight of 15 g/m² formed from PSS, the back sheets 4B and 5B arerespectively formed from a spun-bonded non-woven fabric having a basisweight of 17 g/m² formed from PP, and the connecting sheet 6 is formedfrom an SMS non-woven fabric having a basis weight of 15 g/m² formedfrom PP.

In addition, an elastic member 4WG is provided in the front piece 4around the upper edge 4U, an elastic member 4LG is provided in the frontpiece 4 around the lower edge 4L, and an elastic member 4FG is providedin the front piece 4 between the elastic member 4WG and the elasticmember 4LG. As shown in FIG. 3, a folded portion 4F is provided aroundthe upper edge 4U in which the back sheet 4B is folded to the side ofthe top sheet 4T, and the elastic member 4WG is anchored between theback sheets 4B at the folding portion 4F. On the other hand, the elasticmembers 4FG and 4LG are anchored between the top sheet 4T and the backsheet 4B.

Similarly, an elastic member 5WG is provided in the back piece 5 aroundthe upper edge 5U, an elastic member 5LG is provided in the back piece 5around the lower edge 5L, and an elastic member 5FG is provided in theback piece 5 between the elastic member 5WG and the elastic member 5LG.A folded portion 5F is provided around the upper edge 5U in which theback sheet 5B is folded to the side of the top sheet 5T, and the elasticmember 5WG is anchored between the back sheets 5B at the folding portion5F. On the other hand, the elastic members 5FG and 5LG are anchoredbetween the top sheet 5T and the back sheet 5B. These elastic members4WG, 4FG, 4LG, 5WG, 5FG and 5LG are in the form of threads, for example,and are attached to the front piece 4 and the back piece 5 in astretched state.

In this case, the elastic member 5FG includes an elastic member 5FGWprovided in the waist portion 5W of the back piece 5 and an elasticmember 5FGE provided in the extending portion 5E. As can be understoodfrom FIG. 2, the elastic member 5FGE is provided overlapping the innerbody 3 and the leakage preventing member 7. This elastic member 5FGEprovides elastic action between the side areas 1F and crotch area 10 ofthe diaper 1 when worn.

In addition, the elastic members 4LG and 5LG extend continuously withoutbeing interrupted in the front piece 4 and the back piece 5, and areprovided overlapping with the outer body 3, the connecting sheet 6 andthe leakage preventing members 7. These elastic members 4LG and 5LG alsoprovide elastic action between the side areas 1F and the crotch area 10of the diaper when worn.

Note that the upper edges of the top sheets 4T and 5T are arrangedroughly along the lower edges of the elastic members 4WG and 5WG, whilethe lower edges of the top sheets 4T and 5T are arranged roughly alongthe lower edges of the back sheets 4B and 5B.

The elastic members 4WG, 4FG, 4LG, 5WG, 5FG and 5LG are formed fromelastic fibers in the manner of natural rubber, synthetic rubber orspandex fibers, and have a draw ratio of, for example, 1.3 to 3.5. Inthe case the elastic members 4WG, 4FG, 4LG, 5WG, 5FG and 5LG are formedfrom spandex, the thickness of the elastic members 4WG, 4FG, 4LG, 5WG,5FG and 5LG is, for example, 300 dtex to 1200 dtex. In the firstembodiment according to the present invention, the elastic members 4WGand 5WG are respectively formed from spandex having a thickness of 940dtex and draw ratio of 3.0, the elastic members 4FG and 5FG are formedfrom spandex having a thickness of 780 dtex and draw ratio of 2.5, theelastic members 4LG are formed from spandex having an average draw ratioof 2.5, and the elastic members 5LG are formed from spandex having anaverage draw ratio of 2.2. In addition, the elastic member 4WG and theelastic member 5WG respectively contain 5 spandex fibers, the elasticmember 4FG contains 10 spandex fibers, the elastic member 5FGW of thewaist portion 5W contains 11 spandex fibers, and the elastic member 5FGEof the extending portion 5E contains 2 spandex fibers. Note that theelastic members 4WG, 4FG, 4LG, 5WG, 5FG and 5LG may also be formed fromelastic sheets.

As is shown in FIGS. 3 and 4, the inner body 3 is provided with a liquidpermeable top sheet 3T, a liquid impermeable back sheet 3B and anabsorptive body 3A arranged between the top sheet 3T and the back sheet3B. In addition, the absorptive body 3A is provided with an absorptivebody core 3AC and a wrapping sheet 3AW that envelops the absorptive bodycore 3AC.

Widened portions 3ACW are formed on both ends in the lengthwisedirection and/or longitudinal direction LN of the absorptive body core3AC and at an intermediate portion between both ends, and these widenedportions 3ACW are mutually connected by narrowed portions 3ACN.

In addition, a plurality of slits 3ACS are provided in the absorptivebody core 3AC that extend in the lengthwise direction and/orlongitudinal direction LN. These slits 3ACS include a central slitpositioned substantially in the center in the transverse direction LT,and side slits positioned on both sides of the central slit. In thefirst embodiment according to the present invention, the length of thecentral slit is 320 mm and the width is 12 mm, while the length of theside slits is 80 mm and the width is 10 mm. This being the case, theabsorptive body core 3AC easily bends along the slits 3ACS, therebyfacilitating adherence of the absorptive body 3A to the wearer.

The top sheet 3T is formed from a hydrophilic non-woven fabric formedfrom polyolefin-based fibers or PET fibers and the like that ismanufactured by a manufacturing method such as spunbonding orair-through bonding. The back sheet 3B is formed from a water-resistantand moisture-permeable film formed from PE and the like. The absorptivebody core 3AC is formed from pulp, superabsorbent polymer (SAP) ormixture thereof. The wrapping sheet 3AW is formed from a hydrophilicnon-woven fabric formed from polyolefin-based fibers or PET fibers andthe like that is manufactured by a manufacturing method such asspunbonding or air-through bonding. In the first embodiment according tothe present invention, the top sheet 3T is formed from a non-wovenfabric manufactured by air-through bonding and having a basis weight of25 g/m², the back sheet 3B is formed from a moisture-permeable PET filmhaving a basis weight of 22 g/m², the absorptive body core 3AC is formedfrom a single mixed layer of pulp having a basis weight of 250 g/m² andSAP having a basis weight of 200 g/m², and the wrapping sheet 3AW isformed from an SMS non-woven fabric having a basis weight of 13 g/m².

As is shown in FIG. 4, each of the leakage preventing members 7 hasanchored edges and/or inner edges 781 anchored to the outer body 2 orthe inner body 3, and free edges and/or outer edges 780 not anchored tothe outer body 3 or the inner body 2. In addition, each of the leakagepreventing members 7 includes a liquid impermeable sheet 7SH and elasticmembers 7G, and the liquid impermeable sheet 78H includes a leakagepreventing non-woven fabric 7SHN and a leakage preventing film 78HF. Inthe outer edges 780 of each of the leakage preventing members 7, theleakage preventing non-woven fabric 78HN is folded and overlaps theouter edges of the leakage preventing film 7SHF, and the elastic members7G are anchored between the folded leakage preventing non-woven fabric7SHN. Note that the outer edges of the leakage preventing film 7SHF donot reach to the outer edges 7S0 of the leakage preventing members 7. Onthe other hand, in the inner edges 7SI of each of the leakage preventingmembers 7, the edges of the leakage preventing non-woven fabric 7SHN andthe leakage preventing film 7SHF are substantially mutually arranged inrows.

When worn, each of the leakage preventing members 7 rises up towards thewearer to act as leakage preventing barriers.

The leakage preventing non-woven fabric 7SHN is formed frompolyolefin-based fibers or PET fibers and the like, and is manufacturedby a method such as spun bonding. The leakage preventing film 7SHF isformed from polyethylene (PE) or PET and the like. In the firstembodiment according to the present invention, the leakage preventingnon-woven fabric 7SHN is formed from hydrophobic SMS non-woven fabrichaving a basis weight of 15 g/m², and the leakage preventing film 7SHFis formed from a moisture-permeable PE film having a basis weight of 18g/m². The elastic members 7G are formed from elastic fibers in themanner of natural rubber, synthetic rubber or spandex fibers. In thefirst embodiment according to the present invention, the elastic members7G are formed from two spandex fibers having a thickness of 620 dtex anddraw ratio of 2.2.

Connection and/or anchoring of these members are carried out by, forexample, heat sealing, sonic sealing or an adhesive and the like. A hotmelt adhesive (HMA) containing, for example, styrene-isoprene-styrene(SIS), styrene-butadiene-styrene (SBS) orstyrene-ethylene-butylene-styrene (SEBS) adhesive can be used for theadhesive.

More specifically, the top sheets 4T and 5T and back sheets 4B and 5B ofthe front piece 4 and the back piece 5 are mutually connected to theelastic members 4WG, 4FG, 5WG and 5FG with a preliminarily applied HMA.In addition, at those locations where the elastic members 4WG, 4FG, 5WGand 5FG are sparse, namely where the interval between elastic membersis, for example, 10 mm or more, HMA is applied to the top sheets 4T and5T and the back sheets 4B and 5B by a coating method in the manner ofspiral coating or controlled seam coating. Moreover, HMA is also appliedto the top sheets 4T and 5T and the back sheets 4B and 5B around thelower edges 4L and 5L in order to prevent separation.

On the other hand, the elastic members 4LG and 5LG are anchored to thetop sheets 4T and 5T by HMA preliminarily applied to the top sheets 4Tand 5T by a coating method such as spiral coating. In this case, the HMAis applied so as to follow the loci of the elastic members 4LG and 5LG.

In addition, the connecting sheet 6 is connected to the front piece 4and the back piece 5 by a method such as sonic sealing or adhesive. Inthe first embodiment according to the present invention, HMA ispreliminarily applied to the back of the connecting sheet 6 by a coatingmethod such as slot coating.

On the other hand, in the inner body 3, the top surface and bottomsurface of the absorptive body core 3AC are connected to the corewrapping sheet 3AW by an adhesive such as HMA. In this case, theadhesive is applied by a coating method such as spiral coating, slotcoating, controlled seam coating, bead coating or curtain coating so asto have a basis weight of 1.5 g/m² to 10 g/m². In the first embodimentaccording to the present invention, HMA is applied by a spiral coatingmethod so as to have a basis weight of 5 g/m².

In addition, HMA is applied to the back sheet 3B of the inner body 3 orside of the leakage preventing members 7 facing the outer body 2 by acontrolled seam coating method, and as a result thereof, the inner body3 and the leakage preventing members 7 are anchored to the front piece4, the back piece 5 and the connecting sheet 6.

In the leakage preventing members 7, HMA is applied to the elasticmembers 7G by a slit nozzle method, and the elastic members 7G areanchored to the leakage preventing non-woven fabric 7SHN by this HMA. Inaddition, the leakage preventing non-woven fabric 7SHN and the leakagepreventing film 7SHF are mutually joined by applying HMA to the leakagepreventing non-woven fabric 7SHN by spiral coating.

Note that, in the side areas 1F of the diaper 1, the front piece 4around both side edges 4S and the back piece 5 around both side edges 5Sare mutually joined by a method such as heat sealing or ultrasonicsealing. Note that the front piece 4 and the back piece 5 may berefastenably joined, and in this case, mechanical fasteners containinghooks and loops can be used.

The edges 1LE that define the legs holes 1L are formed by the sideportions 4LS of the lower edge 4L of the front piece 4, the sideportions 5LS of the lower edge 5L of the back piece 5, and both edges 6Sof the connecting sheet 6. In this case, the edges 1LE are formed by asingle cutting action and are smoothly curved and continuing.

In the first embodiment according to the present invention, at least aportion of both side edges 6S of the connecting sheet 6 are positionedfarther to the inside in the transverse direction LT than both sideedges 3S of the inner body 3 in the spacing area SP between the frontpiece 4 and the back piece 5 as was previously described. Thus, therange of movement of the legs of a wearer can be increased whilemaintaining a large absorptive surface for the inner body 3. Namely,difficulty encountered by a wearer when moving the legs can be inhibitedwhile maintaining favorable absorptive performance of the inner body 3.

At the same time, the end portions 6SE of the connecting sheet 6 arepositioned farther to the outside in the transverse direction LT thanboth side edges 3S of the inner body 3 (FIG. 2). As a result, the frontpiece 4 and the back piece 5 can be reliably connected to the connectingsheet 6 while facilitating movement of the legs of a wearer.

Moreover, since the extending portion 5E having the elastic member 5FGEis provided in the back piece 5, the shape of the diaper 1 can be madeto be that of an undergarment, and the entire gluteal region of thewearer is covered by the back piece 5. Thus, leakage can be suppressedand apprehension of the wearer concerning leakage can be reduced.

Moreover, since the inner body 3 is pulled up towards the side areas 1F(FIG. 1) by the elastic members 5FGE, 4LG and 5LG, twisting of the innerbody 3 to the inside is suppressed, thereby maintaining absorptiveproperties of the inner body 3.

What is more, since the edges 1LE that define the leg holes 1L arecontinuing by curving smoothly, they have a curved shape that followsthe legs of a wearer, thereby enhancing adherence to the wearer.

Moreover, the length of the connecting sheet 6 can be shorter than thelength of the inner body 3. Thus, the amount of the connecting sheet 6can be decreased, thereby making it possible to reduce costs.

Moreover, the connecting sheet 6 is softer than the front piece 4 andthe back piece 5 as was previously described. As a result, in comparisonwith the case of having two sheets in the crotch area 1C as a result ofthe entire outer body 2 being provided with a top sheet and a backsheet, the connecting sheet and/or inner body 2 makes soft contact withthe legs and/or groin region of a wearer and the legs of the wearerbecome easier to move. In addition, even if the outer body 2 rolls upand becomes wrinkled, the wearer is less likely to feel a sense oftightness. Moreover, since the connecting sheet 6 is formed from asingle sheet, costs can be reduced in comparison with the case of theentire outer body 2 being formed from a top sheet and back sheet.

In addition, since the connecting sheet 6 can be formed from a materialdiffering from that of the front piece 4 and the back piece 5, costperformance of the diaper 1 can be enhanced. Namely, if the connectingsheet 6 is formed from a moisture permeable or moisture absorptivematerial, breathability in the crotch area 1C can be improved. Anon-woven fabric containing cellulose-based fibers such as rayon or pulpand polyester fibers can be used as a moisture absorptive material. Morespecifically, a non-woven fabric containing rayon, polyolefin-basedfibers and polyester fibers (such as a non-woven fabric manufactured byspun lacing and having a basis weight of 26 g/m²) or a non-woven fabriccontaining pulp and polyester (such as a non-woven fabric manufacturedby spun lacing and having a basis weight of 40 g/m²) is used.

In addition, twisting of the inner body 3 to the inside can besuppressed by providing the connecting sheet 6. Consequently, theleakage preventing members 7 reliably rise up towards the wearer.Namely, the connecting sheet 6 provides a starting point for the leakagepreventing members 7 to rise up towards the wearer.

Next, an explanation is provided of the manufacturing method of thediaper 1 of the first embodiment according to the present invention withreference to FIG. 5.

With reference to FIG. 5, the manufacturing method of the firstembodiment according to the present invention comprises a step ST1 formanufacturing the inner body 3 provided with the leakage preventingmembers 7, a step ST2 for manufacturing the connecting sheet 6, and astep ST3 for manufacturing a continuous body of the diaper 1 in the formof a web W1.

In the step ST1, the absorptive body core 3AC in which the slits SACShave been preliminarily formed is first wrapped with a continuous bodyof the wrapping sheet 3AW in the form of a wrapping sheet web W3AW(ST11). Note that, in this case, the absorptive body core 3AC istransported so that the slits 3ACS are parallel to a machine directionMD.

Next, continuous bodies of the top sheet 3T and back sheet 3B in theform of top sheet web W3T and back sheet web W3B are respectivelyaffixed to the upper surface and lower surface of the wrapping sheet webW3AW wrapped around the absorptive body core 3AC to form a continuousbody of the inner body 3 in the form of an inner body web W3 (ST12).

On the other hand, a continuous body equivalent to two leakagepreventing films 7SHF in the form of a leakage preventing film web W7SHFand a continuous body of the elastic members 7G in the form ofcontinuous elastic bodies W7G are attached to a continuous bodyequivalent to two leakage preventing non-woven fabrics 7SHN in the formof a leakage preventing non-woven fabric web W7SHN (ST13). Next, theleakage preventing non-woven fabric web W7SHN is divided along themachine direction MD to form a continuous body of the leakage preventingmembers 7 in the form of leakage preventing member webs W7 (ST14).

Next, each leakage preventing member web W7 is affixed to the back ofthe inner body web W3, namely the back sheet web W3B (ST15).

Next, HMA is applied in a predetermined pattern to the back of the innerbody web W3 and the leakage preventing member webs W7, namely the sideopposing an outer body web W2 (ST16).

Next, the inner body web W3 and the leakage preventing member webs W7are cut to the length of a single finished product to form the innerbody 3 provided with the leakage preventing members 7 (ST17).

In step ST2, HMA is applied to the bottom of a continuous body of theconnecting sheet 6 in the form of a connecting sheet web W6 (ST21).

Next, the connecting sheet web W6 is cut to the length of a singlefinished product to form the connecting sheet 6 (ST 22).

In step ST3, a top sheet web W45T is divided along the machine directionMD to form a continuous body of the top sheet 4T of the front piece 4 inthe form a top sheet web W4T and a continuous body of the top sheet 5Tof the back piece 5 in the form of a top sheet web W5T (ST31).Similarly, a back sheet web W45B is divided along the machine directionMD to form a continuous body of the back sheet 4B of the front piece 4in the form of a back sheet web W4B and a continuous body of the backsheet 5 of the back piece 5 in the form of a back sheet web W5B (ST32).The top sheet web W4T and the back sheet web W5B are transported alongthe machine direction MD separated by the spacing area SP in across-machine direction CD substantially perpendicular to the machinedirection MD.

In addition, continuous bodies of the elastic members 4WG and 5WG in theform of continuous elastic bodies W4WG and W5WG as well as continuousbodies of the elastic members 4FG and 5FG in the form of continuouselastic bodies W4FG and W5FG are respectively attached to the back sheetwebs W4B and W5B while being stretched in the machine direction MD(ST33).

In addition, continuous bodies of the elastic members 4LG and 5LG in theform of continuous elastic bodies W4LG and W5LG are respectivelyattached to the top sheet webs 4WT and W5T while being stretched atsubstantially the same location at which the continuous elastic bodiesW4WG, W5WG, 4FG and W5FG are supplied (ST33A). Note that, in FIG. 5, thecontinuous elastic bodies W4LG and W5LG are depicted as being attachedto the back sheet webs W4B and W5B for the sake of legibility. Inaddition, the continuous elastic bodies W4LG and W5LG may also beattached to the back sheet web W4B and W5B.

Next, the top sheet webs W4T and W5T are respectively overlapped andpressed onto the back sheet webs W4B and W5B to form continuous bodiesof the front piece 4 and the back piece 5 in the form of a front pieceweb W4 and a back piece web W5 (ST34). As a result, the continuousbodies W4WG, W5WG, W4FG, W5FG, W4LG and W5LG are held on the back sheetwebs W4B and W5B and the top sheet webs W4T and W5T.

In addition, the outer edges of the back sheet webs W4B and W5B arefolded to form folded portions 5F (ST35).

In addition, the connecting sheet 6 is attached to the front piece webW4 and the back piece web W5 at intervals in the machine direction MD soas to straddle the spacing area SP, and as a result thereof, acontinuous body of the outer body 2 in the form of the outer body web W2is formed (ST36).

Note that, in the case of making the areas around both ends of theconnecting sheet 6 in the longitudinal direction LN to be sandwichedbetween the top sheets 4T and 5T and the back sheets 4B and 5B, theconnecting sheet 6 is first attached to the top sheet webs W4T and W5T,after which the back sheet webs W4B and W5B are overlapped with theconnecting sheet 6 and the top sheet webs W4T and W5T. Alternatively,the connecting sheet 6 is first attached to the back sheet webs W4B andW5B, after which the top sheet webs W4T and W5T are overlapped with theconnecting sheet 6 and the back sheet webs W4B and W5B.

Next, a cutting action is carried out on the outer body web W2 at aninterval in the machine direction MD to form the edges 1LE that definethe leg holes 1L (ST37). In this case, the front piece web W4 and theback piece web W5 are cut along the elastic members 4LG and 5LG. Inaddition, the connecting sheet 6 is cut so that both side edges 6S ofthe connecting sheet 6 are curved inward, or so that at least a portionof both side edges 6S of the connecting sheet 6 in the spacing area SPare positioned farther to the inside in the transverse direction LT thanboth side edges 3S of the inner body 3. Note that cutting action iscarried out once along an annular cutting line CT, for example. Thetrimmed material is recovered in this case.

Next, the inner body 3 provided with the leakage preventing members 7 isattached to the front piece web W4, the back piece web W5 and theconnecting sheet 6 to form the diaper web W1 (ST38). Note that guidesare preferably provided immediately before the cutting action and actionfor attaching the inner body 3 so that the position of the outer bodyweb W2 in the cross-machine direction CD is at the proper position.

Next, the diaper web W1 is folded along a folding line FL lying in themachine direction MD (not shown). In this case, the folding line FL maybe in the center of the diaper web W1 in the cross-machine direction CDor may be shifted from the center.

Next, the front piece web W4 and the back piece web W5 are partiallyjoined at intervals in the machine direction MD to form joined portionsas a result thereof. Next, the diaper web W1 is cut at these joinedportions in the cross-machine direction CD to form the diaper 1 (notshown).

In providing an explanation of steps ST33A, ST34, ST36 and the like withreference to FIG. 6, the top sheet webs W4T and W5T are respectivelytransported towards a roller R1, while the back sheet webs W4B and W5Bare respectively transported towards a roller R2.

Prior to reaching the roller R1, the stretched continuous elastic bodiesW4LG and W5LG are supplied and attached to the top sheet webs W4T andW5T while oscillating in the cross-machine direction. In addition, priorto this, HMA is supplied from an HMA applicator AST to the top sheetwebs W4T and W5T so as to match the loci of the continuous elasticbodies W4LG and W5LG. On the other hand, prior to reaching the rollerR2, stretched continuous elastic bodies W4WG, W5WG, W4FG and W5FG aresupplied to the back sheet webs W4B and W5B.

Since the rollers R1 and R2 are mutually adjacent, the top sheet websW4T and W5T and the back sheet webs W4B and W5B are overlapping on therollers R1 and R2, respectively. At this time, the continuous elasticbodies W4WG, W5WG, W4FG, W5FG, W4LG and W5LG are sandwiched between thetop sheet webs W4T and W5T and the back sheet webs W4B and W5B. Notethat, as was previously described, HMA is preliminarily applied to thecontinuous elastic bodies W4WG, W5WG, W4FG and W5FG, and the continuouselastic bodies W4WG, W5WG, W4FG and W5FG are attached to the top sheetwebs W4T and W5T and the back sheet webs W4B and W5B by this HMA.

The mutually overlapped top sheet webs W4T and W5T and back sheet websW4B and W5B are then transported by a main drum M and pressed togetherby a press roller RP. As a result, the continuous elastic bodies W4WG,W5WG, W4FG, W5FG, W4LG and W5LG are attached to the top sheet webs W4Tand W5T and the back sheet webs W4B and W5B to form the front piece webW4 and the back piece web W5. The front piece web W4 and the back pieceweb W5 then reach a suction transfer roller RS and are transported whilebeing suctioned and held thereby.

On the other hand, following application of HMA by the HMA applicatorAS6, the connecting sheet web W6 is transported to a cutter CTR and cutto form the connecting sheet 6. This connecting sheet 6 isdiscontinuously attached to the front piece web W4 and the back pieceweb W5 on the suction transfer roller RS. The outer body web W2 isformed in this manner.

Next, the outer body web W2 is transported by a belt conveyor BCtraveling over a suction box SB. This being the case, the outer body webW2 can be suppressed from shifting out of position and forming wrinkles.Note that the suction box SB is preferably formed so that suction actionis applied to the front piece web W4 and the back piece web WS withoutbeing applied to the spacing area SP.

The top sheet webs 4WT and 5WT as viewed from arrows A, B and C in FIG.6 are respectively shown in FIGS. 7(A), 7(B) and 7(C). Note that thecontinuous elastic bodies W4WG, W5WG, W4FG and W5FG are omitted fromFIGS. 7(A), 7(B) and 7(C).

In this manner, in the first embodiment according to the presentinvention, cutting action for forming the edges ILE that define the legholes 1L is carried out after the connecting sheet 6 is connected to thefront piece web W4 and the back piece web W5. As a result, cuttingaction can be carried out with the outer body web W2, namely the frontpiece web W4 and the back piece web W5 mutually connected to theconnecting sheet 6, free of wrinkles as a result of respectively pullingto the outside in the cross-machine direction CD. Thus, the leg holes 1Lcan be formed in the proper shape. In addition, the outer body 3 can beattached to the inner body web 2 without wrinkling. Thus, the inner body3 can be reliably attached to the inner body web W2.

Namely, there is the risk of wrinkling of the front piece web W4 and theback piece web W5 in the state in which they are not mutually connectedby the connecting sheet 6, and if cutting action is carried out while inthis state, there is the risk of the edges 1LE that define the leg holes1L deviating from the proper shape. In addition, it is also difficult toreliably attach the inner body 3 to the outer body web W2 while in thisstate. On the other hand, when cutting action is carried out, the frontpiece web W4 and the back piece web W5 around the edges 1LE that definethe leg holes 1L become discontinuous in the machine direction MD. Sincethese discontinuous portions are not held in the machine direction MD,there is the risk of these portions being rolled up and flapping about,thereby causing wrinkling or flapping of the front piece web W4 and theback piece web W5. Moreover, when such discontinuous portions areformed, the continuous elastic bodies W4LG and W5LG, for example, of thefront piece web W4 and the back piece web W5 contract in thecross-machine direction CD, again resulting in the risk of wrinkling orflapping of the front piece web W4 and the back piece web W5. When theconnecting sheet 6 or the inner body 3 is attempted to be attached tothe front piece web W4 and the back piece web W5 in which wrinkling orflapping has occurred, the connecting sheet 6 or the inner body 3 is notreliably connected to the front piece web W4 and the back piece web W5,thereby resulting in the risk of a decrease in productivity of thediaper 1.

In contrast, in the first embodiment of the present invention, after thefront piece web W4 and the back piece web W5 are mutually connected bythe connecting sheet 6, cutting action is carried out for forming theedges 1LE followed by attachment of the inner body 3. Thus, problemslike those described above do not occur. Note that these problems areunique to methods of manufacturing the diaper 1 in which the front piece4 and the back piece 5 are formed from separate sheets, and do not occurin methods of manufacturing diapers in which the front piece and theback piece are formed from a single sheet.

In addition, cutting action for forming the edges 1LE is not carried outon the inner body 3, thereby eliminating the risk of the inner body 3being damaged by this cutting action. Thus, productivity of the diaper 1can be maintained at a high level.

In addition, in the first embodiment according to the present invention,the connecting sheet 6 is not attached to the front piece web W4 and theback sheet web W5 in the form of a web, but rather is attached afterhaving cut to an amount equivalent to a single finished product. As aresult, costs incurred for the connecting sheet 6 can be reducedconsiderably. This is because, if the connecting sheet 6 is attached inthe form of a web, the majority of the connecting sheet 6 ends up beingremoved by the cutting action.

Moreover, since the connecting sheet is attached discontinuously, theend portions 6SE can be positioned farther to the inside in thetransverse direction LT than the side portions 4LS of the front piece 4and the side portions 5LS of the back piece 5 that define the leg holes1L. As a result, the connecting sheet 6 is not present around the sideportions 4LS and 5LS, thereby improving comfort when worn.

Namely, FIG. 21 shows the case of the connecting sheet web W6 beingattached to the front piece web W4 and the back piece web W5, and inthis case, end portions 6SE′ on the side of the back piece 5 coincidewith the side portions 5LS, and the connecting sheet 6 is thereforepresent around the side portions 5LS. In addition, portions 6′ of theconnecting sheet 6 that overlap the front piece 4 extend to the sideedges 4S of the front piece 4 along the side portions 4LS, and theconnecting sheet 6 is therefore present around the side portions 4LS. Asa result, the areas around the side portions 4LS and 5LS becomecomparatively hard, thereby resulting in the risk of imparting a senseof discomfort to the legs of a wearer.

In contrast, in the first embodiment according to the present invention,since the end portions 6SE are positioned farther to the inside in thetransverse direction LT than the side portions 4LS and 5LS, theaforementioned problems do not occur. Moreover, since the surface areaof the connecting sheet 6 can be decreased, material costs can bereduced. Note that the end portions 6SE are not necessarily required toextend in the transverse direction LT, but rather may also have a curvedshape. In addition, only one of the end portions 6SE on the side of thefront piece 4 and the end portions 6SE on the side of the back piece 5may be positioned farther to the inside in the transverse direction LTthan the side portions 4LS and 5LS.

Moreover, as was explained with reference to FIG. 6, since theconnecting sheet 6 is attached to the front piece web W4 and the backpiece web W5 that are suctioned and held, the connecting sheet 6 can beattached at the proper positions on the front piece web W4 and the backpiece web W5.

FIG. 8 shows an adhesive application pattern in step ST16.

As shown in FIG. 8, the width of an area AZ where an adhesive is appliedvaries along the longitudinal direction LN. Namely, the adhesiveapplication area AZ has end areas AZE located on both ends in thelongitudinal direction LN, a central area AZC located in the center inthe longitudinal direction LN, and an intermediate area AZI locatedbetween the end area AZE and the central area AZC on the side of theback piece 5. Here, both end areas AZE and the intermediate area AZI donot overlap with the connecting piece 6, but rather the central area AZCoverlaps with the connecting sheet 6.

The widths of both end areas AZE substantially coincide with the entirewidth of the inner body 3 and the leakage preventing members 7, andconstitutes the largest width. This is to prevent the inner body 3 andthe leakage preventing members 7 from separating from the front piece 4and the back piece 5 and eliminate a sense of discomfort on the part ofa wearer.

The width of the central area AZC is narrower than the width of theinner body 3 and constitutes the smallest width. In the first embodimentaccording to the present invention, the width of the central area AZC isabout 90 mm.

The width of the intermediate area AZI is intermediate to the width ofboth end areas AZE and the central area AZC.

In this case, since adhesive is not applied to both sides in thetransverse direction LT of the central area AZC and the intermediatearea AZI, non-anchored areas NC are formed where the inner body 3 andthe leakage preventing members 7 are not anchored to the outer body 2.The width of the non-anchored area NC around the central area AZC islarger than the width of the non-anchored area NC around theintermediate area AZI. Moreover, a non-anchored area NC is also formedin the center in the transverse direction of the central area AZC.

In this manner, a portion around the outer body 2, namely both edges 6Sof the connecting sheet 6, and the inner body 3 are not mutuallyanchored between the front piece 4 and the back piece 5. Thus, the innerbody 3 easily deforms corresponding to the physique of the wearerthereby enhancing adherence of the inner body 3.

The leakage preventing members 7 rise up by using as starting pointsedges AZS located on both sides in the transverse direction of thecentral area AZC and the intermediate area AZI. Thus, as a result ofincreasing the size of the non-anchored area NC around the central areaAZC, the amount of the rise of the leakage preventing members 7 can beincreased. In addition, adherence of the inner body 3 to the wearer canbe enhanced.

In contrast, the non-anchored area NC around the intermediate area AZIis reduced in size, thereby suppressing rising of the leakage preventingmembers 7. As a result, excessive rising of the leakage preventingmembers 7 that causes them to cover the absorptive surface of the innerbody 3 is prevented. In addition, if the intermediate area AZI isprovided on the side of the back piece 5, namely the gluteal region ofthe wearer, the leakage preventing members 7 can be prevented fromriding up into the seat of the gluteal region, thereby enhancing thesense of comfort.

Note that, in step ST16 (FIG. 5), the previously described patternformation can be facilitated by applying adhesive in the machinedirection MD of the inner body web W3 and the leakage preventing memberwebs W7.

Note that, as shown in FIG. 9(A), the width of the intermediate area AZImay be made to substantially coincide with the entire width of the innerbody 3 and the leakage preventing members 7. In this case as well,excessive twisting of the leakage preventing members 7 can be prevented.Note that the non-anchored area NC in the center in the longitudinaldirection LN is omitted in this example.

Alternatively, as shown in FIG. 9(B), non-anchored areas NC may also beprovided adjacent to both end areas AZE. This being the case, wrinklingand twisting of the inner body 3 are suppressed. As a result, the senseof comfort is enhanced and stable absorptive performance of the innerbody 3 is maintained.

FIG. 10 shows a second embodiment according to the present invention.

In this second embodiment according to the present invention, theelastic members 4LG and 5LG are omitted. Namely, the step for applyingHMA for attaching the continuous elastic bodies W4LG and W5LG, and thestep for attaching the continuous elastic bodies W4LG and W5LG to thetop sheet webs W4T and W5T are omitted.

FIG. 11 shows a third embodiment according to the present invention.

In this third embodiment, the elastic members 4LG and 5LG are provideddiscontinuously. Namely, although the elastic members 4LG and 5LG areprovided along the side portions 4LS and 5LS of the corresponding loweredges 4L and 5L, they are not provided along the central portions 4LCand 5LC.

In providing an explanation of the manufacturing method, the continuouselastic bodies W4LG and W5LG are supplied to the top sheet webs W4T andW5T and attached while oscillating in the same manner as the firstembodiment. In this case, as shown in FIG. 12, the continuous elasticbodies W4LG and W5LG are oscillated across the inner edges of thecorresponding top sheet webs W4T and W5T, namely edges W4T1 and W5T1facing the spacing area SP, and as a result thereof, protrude from thetop sheet webs W4T and W5T. Next, protruding portions P4 and P5 of thecontinuous elastic bodies W4LG and W5LG are cut and removed.Discontinuous elastic members 4LG and 5LG are formed in this manner.

FIG. 13 shows a fourth embodiment according to the present invention.

In this fourth embodiment, the elastic member 4LG is provided with theelastic member 5LG is omitted. The elastic member 4LG may be continuousor discontinuous. However, if the elastic member 4LG of the front piece4 is provided discontinuously, namely if the elastic member 4LG does notoverlap with the inner body 3 or the connecting sheet 6, narrowing ofthe width of the inner body 3 on the abdominal side is suppressed. Thus,this is particularly preferable in the case the wearer is a male. On theother hand, in the case of providing the elastic member 4LGcontinuously, if the elastic member 4LG is provided adjacent to theurogenital region of women, adherence of the inner body 3 is enhanced.Alternatively, if the elastic member 4LG is provided to as to pass belowthe male genitalia, a space can be formed within the diaper 1, therebyenhancing comfort for male wearers. In addition, if the elastic members4LG and 5LG are provided continuously, there is no longer a need to cutand remove the protruding continuous elastic body W5LG. In addition,since the elastic member 5LG overlaps with the inner body 3, the innerbody 3 is further adhered to the wearer.

FIG. 14 shows a fifth embodiment according to the present invention.

In this fifth embodiment, the elastic member 5LG is provided while theelastic member 4LG is omitted.

A sixth embodiment according to the present invention is indicated inFIGS. 15 to 17.

In this sixth embodiment, the top sheets 4T and 5T are formed from anon-stretchable non-woven fabric, while the back sheets 4B and 5B areformed from a stretchable sheet as shown in FIGS. 15 and 16.

A stretchable non-woven fabric containing, for example, stretchablethermoplastic fibers and elastomer fibers can be used for thestretchable sheet. In addition, polyolefin-based fibers in the manner ofpolypropylene or polyethylene fibers or polyester-based fibers in themanner of polyethylene terephthalate or polypropylene terephthalatefibers can be used for the thermoplastic fibers. In addition,urethane-based fibers such as polyurethane fibers, polystyrene-basedfibers or rubber-based fibers and the like can be used for the elastomerfibers. Moreover, the stretchable non-woven fabric can be manufacturedby a manufacturing method such as spunbonding or air-through bonding.Note that the stretchable non-woven fabric is used after having beengear-stretched to demonstrate stretching in the machine direction MD.

The back sheets 4B and 5B formed from a stretchable sheet in this mannerprovide elastic action between the side areas 1F and crotch area 10 ofthe diaper 1.

Note that the stretchable sheet may be provided continuously ordiscontinuously in the machine direction MD. In addition, thestretchable sheet can be provided in one or both of the front piece 4and the back piece 5.

As shown in FIG. 17, the back sheet web W45B is affixed to the top sheetweb W45T while stretched in the machine direction MD (ST70). Note that,at this time the continuous elastic bodies W4WG, W5WG, W4FG and W5FG towhich adhesive has been applied are already supplied onto the top sheetweb W45T.

Next, the top sheet web W45T is folded back at both side edges in themachine direction MD and overlapped with the back sheet web W45B (ST71).As a result, an integrated web WI is formed in which the back sheet webW45B and the continuous elastic bodies W4WG, W5WG, W4FG and W5FG areintegrated into a single unit.

Next, the integrated web WI is divided into the front piece web W4 andthe back piece web W5 (ST72). Next, the connecting sheet 6 is connectedto the front piece web W4 and the back piece web W5 (ST73) to form theedges 1LE that define the leg holes 1L (ST74). Next, the inner body 3 isattached (ST75).

Note that, since the back sheet web W45B stretches in the machinedirection MD and contracts in the cross-machine direction CD, a positioncontroller is provided before each processing location so that thewidths of the integrated web WI, front piece web W4 and back piece webW5 in the cross-machine direction CD are maintained at the propervalues.

In the aforementioned sixth embodiment, the front piece 4 and the backpiece 5 are formed from a mutually overlapping stretchable sheet andnon-stretchable non-woven fabric. However, at least a portion of thefront piece 4 or the back piece 5, such as a portion around the legholes 1L, can also be formed from only a stretchable sheet. In thiscase, the portion formed only from the stretchable sheet is formed fromone or a plurality of stretchable sheets. In the case of forming thisportion from a stretchable non-woven fabric in the manner of astretchable urethane spun-bond fabric, the basis weight of that portionis preferably 50 g/m² or more, and for example, 80 g/m². This being thecase, stretchability of the front piece 4 or the back piece 5 isimproved, or in other words, the maximum stretched dimension of thefront piece 4 or the back piece 5 becomes larger or stretching occurs inthe longitudinal direction LN of the diaper 1 (see FIG. 2). As a result,the front piece 4 or the back piece 5 closely fits the legs of thewearer around the leg holes 1L thereby resulting in greater comfort.

FIG. 18 shows a seventh embodiment according to the present invention.

In this seventh embodiment as well, the outer body web W2 provided withthe connecting sheet 6 is cut along the cutting line CT to form theedges 1LE that define the leg holes 1L. In this case, the front pieceweb W4 and the back piece web W5 are cut, but the connecting sheet 6 isnot cut. As a result, the connecting sheet 6 maintains a rectangularshape that is free of a narrow portion. As a result, since the frontpiece web W4 and the back piece web W5 are not cut together with thecomparatively soft connecting sheet 6, the load on the cutting bladeused in the cutting action can be reduced, thereby making it possible toextend the life of the cutting blade.

Next, the inner body 3 is attached to the outer body web W2 so as tooverlap the connecting sheet 6. In this case, the entire side edges 6Sof the connecting sheet 6 are positioned farther to the outside in thetransverse direction LT than both side edges 3S of the outer body 3.This being the case, the effect of the inner body 3 being pulled uptowards the side areas 1F of the diaper 1 (FIG. 1) can be enhanced.

FIG. 19 shows an eighth embodiment according to the present invention.

In this eighth embodiment as well, the outer body web W2 provided withthe connecting sheet 6 is cut along the cutting line CT to form theedges 1LE. In this case, similar to the case of FIG. 18, the front pieceweb W4 and the back piece web W5 are cut, but the connecting sheet 6 isnot cut. Note that, in the example shown in FIG. 19, the areas aroundboth ends of the connecting sheet 6 in the longitudinal direction LN aresandwiched between the top sheet web and the back sheet web of the frontsheet web W4 and the back sheet web W5.

Next, the inner body 3 is attached to the outer body web W2 so as tooverlap the connecting sheet 6. In this case, the entire side edges 6Sof the connecting sheet 6 are positioned farther to the inside in thetransverse direction LT than both side edges 3S of the inner body 3.This being the case, the range of movement of the legs of a wearer canbe increased while maintaining favorable absorptive performance of theinner body 3, while at the same time material costs can be furtherreduced.

FIG. 20 shows a ninth embodiment according to the present invention.

In this ninth embodiment as well, the outer body web W2 provided withthe connecting sheet 6 is cut along the cutting line CT to form theedges 1LE. In this case, the front piece web W4, the back piece web W5and the connecting sheet 6 are cut in the same manner as the case ofFIG. 5.

Next, the inner body 3 is attached to the outer body web W2 so as tooverlap the connecting sheet 6. In this case, similar to the case ofFIG. 18, the entire side edges 6S of the connecting sheet 6 arepositioned farther to the outside in the transverse direction LT thanboth side edges 3S of the inner body 3. As a result, the effect ofpulling up the inner body 3 is enhanced while enabling the leg holes 1Lto be formed to a shape that fits the legs of the wearer.

Note that, in the embodiments described thus far, the front piece web W4and the back piece web W5 are cut at the stage of cutting to form theedges 1LE. However, only one of the front piece web W4 and the backpiece web W5 may be cut.

In addition, the connecting sheet 6 may also not be cut at the stage ofcutting to form the edges 1LE as shown in FIG. 18, for example, or theconnecting sheet may be cut as shown, for example, in FIG. 20.

Therefore, in conceptual terms, at the stage of cutting for forming theedges 1LE, the connecting sheet 6 is cut together with at least one ofthe front piece web W4 and the back piece web W5 so that both edges 6Sin the transverse direction of the connecting sheet 6 are curved inward,or at least one of the front piece web W4 and the back piece web W5 iscut without cutting the connecting sheet 6.

Each of the previously described embodiments can also be mutuallycombined.

REFERENCE SIGNS LIST

-   1 Diaper-   1C Crotch area-   1F Side areas-   1L Leg holes-   2 Outer body-   3 Inner body-   4 Front piece-   5 Back piece-   6 Connecting sheet-   7 Leakage preventing members-   SP Spacing area

The invention claimed is:
 1. A method of manufacturing anunderpants-type absorbent article, which is provided with: an outerbody, provided with a mutually separate front piece, back piece andconnecting sheet, and wherein the front piece and the back piece aremutually joined at side areas and are mutually connected by theconnecting sheet extending in the front-to-rear direction at the crotcharea, and an inner body, containing an absorptive body and which isoverlapped and anchored to the connecting sheet on the inside of theouter body, comprising, in turn: a transport step for transporting acontinuous body of the front piece in the form of a front piece web anda continuous body of the back piece in the form of a back piece web in amachine direction while maintaining a spacing area in a cross-machinedirection perpendicular to the machine direction, an outer body webforming step for forming a continuous body of the outer body in the formof an outer body web by attaching the connecting sheet to the frontpiece web and the back piece web at intervals in the machine directionso as to straddle the spacing area, an edge forming step for cutting theouter body web in order to form edges that define leg holes, and anattachment step for attaching the inner body to the outer body web,wherein, in the edge forming step, the connecting sheet is cut so thatboth edges in the transverse direction of the connecting sheet areinwardly curved, and thus at least a portion of both edges in atransverse direction of the connecting sheet are positioned closer to acenterline of the inner body than both edges in the transverse directionof the inner body in an area between the front piece and the back piece.2. The method according to claim 1, wherein the front sheet web and theback sheet web are respectively provided with a mutually overlapping topsheet web and a back sheet web, and in the outer body web forming step,the areas around both ends of the connecting sheet in a longitudinaldirection are respectively sandwiched between the top sheet web and backsheet web of the front piece web and between the top sheet web and backsheet web of the back piece web.
 3. The method according to claim 1,further comprising a step for attaching elastic members, which providean elastic action between the side areas and the crotch area, to thefront piece web or the back piece web prior to the outer web formingstep.
 4. The method according to claim 3, wherein, in the edge formingstep, the front piece web or the back piece web is cut so as to followthe elastic members.
 5. The method according to claim 1, wherein, in theedge forming step, the outer body web is cut so that the edges thatdefine the leg holes are smoothly curved and continuing.
 6. The methodaccording to claim 1, wherein, in the edge forming step, the connectingsheet is cut together with at least one of the front piece web and theback piece web so that both edges in the transverse direction of theconnecting sheet curve inward, or at least one of the front piece weband the back piece web is cut without cutting the connecting sheet. 7.The method according to claim 1, wherein, in the attachment step, theinner body is attached to the outer body web so that non-anchored areaswhere the connecting sheet and the inner body are not mutually anchored,are formed around both ends in the transverse direction of theconnecting sheet.